Throttle Intake Elbow Replace

Special Service tools

Release Tool - Quick Fit:

310-044 (JD 182)

Release Tool 5/16 - Quick Fit:

310-054 (JD 203)

Removal

1. WARNING:
BEFORE PROCEEDING, IT IS ESSENTIAL THAT THE WARNING NOTES GIVEN IN SECTION ARE READ AND UNDERSTOOD. Service Precautions


Disconnect battery ground cable. Service and Repair

2. Depressurize fuel system. Service and Repair
3. Remove air cleaner cover / intake assembly.
4. Remove throttle body. Electronic Throttle Body, Renew







5. Release intake elbow from right-hand support bracket.
Release brake servo vacuum pipe and disconnect pipe.
Disconnect vacuum pipe.
Remove bolt.







6. Release intake elbow from left-hand support bracket.
Disconnect vacuum pipe.
Disconnect engine breather T-piece.
Remove bolt.
Loosen, but do not remove two bolts.







7. Remove engine covers







8. Disconnect electrical connector from each fuel injector.







9. Disconnect fuel feed hose.
Use special tool 310-044 (JD 1B2).







10. Disconnect fuel return hose.
Use special tool 310-054 (JD 203).







11. Remove intake manifold.
Remove ten bolts.
Remove intake manifold







12. Discard eight seals from intake manifold ports.







13. Remove throttle intake elbow from intake manifold.
Remove seven bolts.
Remove elbow.
Remove seal.
14. Where necessary, remove blanking plate from intake elbow.
Remove bolts.
Discard gasket.
Clean all mating faces.
15. Clean manifold and mating faces on cylinder heads.

Installation
1. Where necessary, install blanking plate to intake elbow.
Install new gasket.
Install bolts (18-24Nm).







2. Install intake elbow to intake manifold.
Install new seal.
Install seven bolts.
3. Install new seals to the eight intake manifold ports. Ensure the seals are fully seated.







4. Install intake manifold. Install ten bolts.
5. Connect fuel feed hose to fuel rail feed pipe. Ensure hose is fully installed.
6. Connect fuel return hose to fuel rail return pipe. Ensure hose is fully installed.







7. Connect electrical connectors to fuel injectors.







8. Install left-hand support bracket to intake elbow and re-connect pipework.
Install bolt.
Tighten two bolts.
Connect breather/purge pipe T-piece.
Connect vacuum pipe.





9. Install right-hand support bracket to intake elbow.
Install bolt.
Connect vacuum pipe.
10. Install throttle assembly. Electronic Throttle Body, Renew
11. Install air cleaner cover / intake assembly.
12. Install engine covers.
13. Reconnect battery ground cable. Service and Repair